Exhaust connector assembly and kit for a segmented exhaust manifold

ABSTRACT

An exhaust manifold assembly for use with an internal combustion engine includes a segmented exhaust manifold with a first segment and a second segment. The first segment has an inlet end for connection with the internal combustion engine and an outlet end. The second segment has an inlet end for connection with the internal combustion engine and an additional inlet end connected with the outlet end of the first segment. An exhaust connector is connected between the outlet end of the first segment and the additional inlet end of the second segment. The exhaust connector includes an inner tubular element, an outer tubular element and a bellows. The outer tubular element is positioned radially around the inner tubular element. The bellows engages the inner tubular element and biases the inner tubular element against the first segment or the second segment. The bellows also engages the outer tubular element and biases the outer tubular element against the other of the first segment or the second segment. The exhaust connector is held in place between the segments using only compressive loading therebetween.

This is a divisional application of application Ser. No. 09/120,691,filed Jul. 22, 1998, now U.S. Pat. No. 6,032,463.

TECHNICAL FIELD

The present invention relates to an exhaust manifold assembly for usewith an internal combustion engine, and, more particularly, to anexhaust connector assembly for connecting manifold segments together ina segmented exhaust manifold assembly.

BACKGROUND ART

An exhaust manifold is used in an internal combustion engine totransport combustion products in the form of exhaust gases away from aplurality of combustion chambers within respective cylinders to theambient environment. A conventional exhaust manifold may be formed as asingle cast metal piece with a plurality of exhaust inlets which areconnected with a plurality of respective cylinders and disposed in fluidcommunication with the corresponding combustion chambers therein.

It is also known to construct an exhaust manifold assembly as asegmented exhaust manifold assembly, including a plurality of individualsegments. Each segment is typically connected with an associatedcylinder of the internal combustion engine and receives combustionproducts therefrom. The plurality of segments are connected togetherusing a plurality of exhaust connectors which are respectively disposedbetween each adjacent pair of segments. The exhaust connectors provide afluid connection between the segments, while at the same time beingconfigured to accommodate varying distances between the segmentsassociated with thermal expansion and contraction during periods ofoperation and inoperation.

A conventional exhaust connector used between segments of a segmentedexhaust manifold assembly may include an axially expandable orcontractible bellows which is attached at both ends thereof to a flange(either through welding or through the use of abutting shoulders). Thepair of flanges are mated with corresponding flanges disposed on anoutlet end of one segment and an inlet end of another segment. Aplurality of bolts extending through mating throughholes on the twopairs of adjacent flanges couple the exhaust connector between the pairof adjacent segments. The bolted connection and generally planarsurfaces between the two flanges may not provide a sufficientmetal-to-metal contact to ensure adequate sealing. Accordingly, gasketsand/or sealants may also be used in the flanged connection between theexhaust connector and manifold segments.

Examples of conventional exhaust connectors for use with a segmentedmanifold assembly are disclosed in U.S. Pat. No. 5,653,478 (McGurk, etal) and U.S. Pat. No. 3,820,829 (Hasselbacher, et al.), each of whichare assigned to the assignee of the present invention.

It is also known to provide a cross-over tube which conducts fluid awayfrom an exhaust nozzle of a gas turbine engine to a blind receivermounted in a sidewall of an aircraft. For example, U.S. Pat. No.5,603,531 (Maier) discloses a cross over tube for use with a gas turbineengine which includes spherical ball joints at each end thereof whichare connected together via sliding tubes. One of the ball joints is heldcaptive within a corresponding female socket of the aircraft. A boltedplate arrangement maintains the spherical ball of the cross over tube inplace, while at the same time allowing a relatively small amount ofangular adjustment.

The present invention is directed to overcoming one or more of theproblems as set forth above.

SUMMARY OF THE INVENTION

The present invention provides an exhaust manifold assembly with anexhaust connector assembly having two sliding tubular elements which arebiased in opposite axial directions against an outlet of one manifoldsegment and an inlet of another manifold segment using a bellows. Theexhaust connector is held in place between the segments using onlycompressive loading therebetween.

In one aspect of the invention, an exhaust manifold assembly for usewith an internal combustion engine includes a segmented exhaust manifoldwith a first segment and a second segment. The first segment has aninlet end for connection with the internal combustion engine and anoutlet end. The second segment has an inlet end for connection with theinternal combustion engine and an additional inlet end connected withthe outlet end of the first segment. An exhaust connector is connectedbetween the outlet end of the first segment and the additional inlet endof the second segment. The exhaust connector includes an inner tubularelement, an outer tubular element and a bellows. The outer tubularelement is positioned radially around the inner tubular element. Thebellows engages the inner tubular element and biases the inner tubularelement against the first segment or the second segment. The bellowsalso engages the outer tubular element and biases the outer tubularelement against the other of the first segment or the second segment.The exhaust connector is held in place between the segments using onlycompressive loading therebetween.

An advantage of the present invention is that the exhaust connectorinterconnects adjacent manifold segments using only axial force appliedby the bellows.

Another advantage is that only a metal-to-metal sealed contact isprovided between the manifold segments and exhaust connector, withoutrequiring the use of additional flanges, bolts or sealant.

Yet another advantage is that the exhaust connector may be easily andsimply installed or removed between the manifold segments using a simpleinstallation/removal tool.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention,and the manner of attaining them, will become more apparent and theinvention will be better understood by reference to the followingdescription of an embodiment of the invention taken in conjunction withthe accompanying drawings, wherein:

FIG. 1 is a plan, partially fragmentary view of an embodiment of anexhaust manifold assembly of the present invention; and

FIG. 2 is an enlarged, fragmentary sectional view of a portion of theexhaust connector shown in FIG. 1, with an embodiment of aninstallation/removal tool of the present invention attached therewith.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplification set out hereinillustrates one preferred embodiment of the invention, in one form, andsuch exemplification is not to be construed as limiting the scope of theinvention in any manner.

BEST MODE FOR CARRYING OUT THE INVENTION

Referring now to the drawings, and more particularly to FIG. 1, there isshown an embodiment of an exhaust manifold assembly 10 for use with aninternal combustion engine (not shown). Exhaust manifold assembly 10generally includes a segmented exhaust manifold 12 with a plurality ofsegments 14 and 16, and an exhaust connector kit 18 including an exhaustconnector 20 and an installation/removal tool 22 which is removablycoupled therewith.

Exhaust manifold 12 is a segmented exhaust manifold including a firstsegment 14 and a second segment 16 which each receive exhaust gas fromrespective cylinder heads of an internal combustion engine. Moreparticularly, first segment 14 and second segment 16 each include aninlet end 24 with a surrounding flange 26 which is attached to acylinder head of an internal combustion engine (not shown) using aplurality of bolts 28. Of course, suitable gaskets and gasket sealantare also likely interposed between flanges 24 and respective cylinderheads of the internal combustion engine.

First segment 14 also includes an outlet end 30 from which the exhaustgas is discharged. Outlet end 30 is coupled with a gas-tight connectionwith an additional inlet end 32 of second segment 16 via exhaustconnector 20. Exhaust gas which is received at both inlet end 24 andadditional inlet end 32 of second segment 16 is merged together anddischarged from outlet end 34. Additional segments (not shown) which aresimilar in construction to second segment 16 are connected together inseries using respective exhaust connectors 20, depending upon the numberof cylinders to which exhaust manifold assembly 10 is connected.Connected in series as such, exhaust manifold assembly 10 accommodates astack-up of thermal tolerances associated with thermal expansion andcontraction during periods of use and inoperation of the internalcombustion engine.

Exhaust connector 20, shown in detail in FIG. 2, is connected betweenoutlet end 30 of first segment 14 and additional inlet end 32 of secondsegment 16. Exhaust connector 20 generally includes an inner tubularelement 36, an outer tubular element 38, and a bellows 40, whichtogether form a substantially gas-tight interconnection between firstsegment 14 and second segment 16, without requiring the use ofadditional flanges, bolts, sealants, etc.

Outer tubular element 38 is positioned radially around and is slidablerelative to inner tubular element 36 in directions generally parallel toa longitudinal axis 42 of inner tubular element 36, as indicated bydouble-headed arrow 44. Each of inner tubular element 36 and outertubular element 38 includes a small chamfer 46 and 48, respectively,which allow outer tubular element 38 to be assembled radially aroundinner tubular element 36. The radial tolerance between inner tubularelement 36 and outer tubular element 38 may vary depending upon thespecific application, but preferably is between 0.001 and 0.003 inch.

Inner tubular element 36 and outer tubular element 38 also each includean angled end face 50 and 52, respectively, which are complementary andmate with respective angled end faces 54 and 56 of first segment 14 andsecond segment 16. Preferably, angled end faces 50 and 52 aresubstantially identically configured and complementary with either ofangled end faces 54 or 56 so that connector 20 may be reversed inorientation between first segment 14 and second segment 16. However, inthe embodiment shown, angled end face 50 of inner tubular element 36 ispositioned against angled end face 54 of first segment 14 so that theexhaust gas discharged from first segment 14 does not directly flow intothe radial clearance space between inner tubular element 36 and outertubular element 38.

Angled end faces 50 and 52 of exhaust connector 20, and correspondinglymating angled end faces 54 and 56 of exhaust manifold 12 are preferablyconfigured so that exhaust connector 20 is substantially self-centeringwhen installed between first segment 14 and second segment 16. Moreparticularly, angled end faces 50, 52, 54 and 56 are formed with curved,spherical mating surfaces which accommodate radial and/or angularmisalignment of exhaust connector 20 between first segment 14 and secondsegment 16. When viewed in cross section, angled end faces 50 and 54 onopposite sides of first segment 14 and exhaust connector 20 have acommon center of curvature as indicated by phantom line 58. In theembodiment shown, inner tubular element 36 as an inside diameter ofapproximately 150 mm, and angled end faces 50 and 54 have a commonradius of curvature of approximately 365 mm. Angled end face 52 of outertubular element 38 and angled end face 56 of second segment 16 aresubstantially identically configured with angled end faces 50 and 54.

Bellows 40 is positioned radially around inner tubular element 36 andaxially adjacent to outer tubular element 38. Bellows 40 includesopposite ends 60 and 62 which respectively engage ends 64 and 66 ofinner tubular element 36 and outer tubular element 38. When exhaustconnector 20 is installed between first segment 14 and second segment16, bellows 40 is compressed a predetermined amount in an axialdirection to provide a corresponding axial loading on each of innertubular element 36 and outer tubular element 38 at ends 60 and 62. Inthe embodiment shown, bellows 40 is constructed from a single layer ofstainless steel (SAE 30321) having a cross sectional thickness ofbetween 0.004 and 0.015 inch. Thus bellows 40 forms a metal-to-metalseal with inner tubular element 36 and outer tubular element 38 at end60 and 62. Alternatively, bellows 40 may be formed from a differentmaterial, with multiple plies of a same material or different materials,with a different cross sectional thickness and/or with a differentnumber and/or amplitude of accordion-type bends to vary the axialloading and thus the effectiveness of the metal-to-metal seal, dependingupon the specific application.

Installation/removal tool 22 is used to selectively install and removeexhaust connector 20 between first segment 14 and second segment 16.Installation/removal tool 22 is positioned at any desired locationaround the periphery of exhaust connector 20 and engages radiallyoutwardly projecting extensions 68 and 70 which respectively projectfrom end face 50 of inner tubular element 36 and end face 52 of outertubular element 38. More particularly, installation/removal tool 22includes an elongate member 72 in the form of a threaded bolt whichincludes threads 74 and defines a longitudinal axis 76. Bolt 72 slidablycarries a jaw 78 and is threadingly engaged with a jaw 80. Jaw 78 isthus free to slide in a longitudinal direction relative to bolt 72, andjaw 80 moves in a longitudinal direction relative to bolt 72 uponrotation of bolt 72 relative to jaw 80. Each of jaws 78 and 80 includean abutment face 82 which engages a corresponding extension 68 or 70.When jaw 78 is against bolt head 84 and jaw 80 is further drawn towardsbolt head 84 through rotation of bolt 72, extensions 68 and 70 of innertubular element 36 and outer tubular element 38 are drawn toward eachother in an axial direction, thereby compressing jaws 40 in an axialdirection. When in such a compressed state, exhaust connector 20 may beinstalled or removed from between first segment 14 and second segment16.

INDUSTRIAL APPLICABILITY

In use, exhaust connector 20 may be installed between first segment 14and second segment 16 of a segmented exhausted manifold 12 by connectinginstallation/removal tool 22 with exhaust connector 20 as describedabove and compressing exhaust connector 20 in an axial direction. Whenin a compressed state, the axial length of exhaust connector 20 is lessthan the distance between outlet end 30 of first segment 14 andadditional inlet end 32 of second segment 16. Exhaust connector 20 maythus be placed between first segment 14 and second segment 16. Bolt 72of installation/removal tool 22 is then rotated to move jaw 80 away frombolt head 84, thereby allowing exhaust connector 20 to expand in theaxial direction to contact each of first segment 14 and second segment16. Spherical end faces 50 and 52 of exhaust connector 20, and 54 and 56of exhaust manifold 12 accommodate angular and radial misalignmentduring installation and allow exhaust connector 20 to be substantiallyself aligning between first segment 14 and second segment 16. Thusinstalled, exhaust connector 20 provides a substantially gas-tightconnection between first segment 14 and second segment 16 duringoperation of the internal combustion engine. To remove exhaust connector20 from exhaust manifold 12, installation/removal tool 22 is againattached to exhaust connector 20 in a manner as described above and usedto compress exhaust connector 20 in an axial direction. When in acompressed state, exhaust connector 20 may again be easily removed frombetween first segment 14 and second segment 16.

Other aspects, objects and advantages of this invention can be obtainedfrom a study of the drawings, the disclosure and the appended claims.

What is claimed is:
 1. An exhaust connector kit for connecting anexhaust connector between segments of a segmented exhaust manifoldassembly, said exhaust connector kit comprising: an exhaust connectorincluding an inner tubular element, an outer tubular element and abellows, said bellows having a pair of ends, said inner tubular elementdefining an axis, said outer tubular element positioned radially aroundand in slidable, substantially sealing contact in an axial directionwith said inner tubular element, said bellows positioned between andengaging each of said inner tubular element and said outer tubularelement, said bellows configured for sealingly compressing one of saidends thereof against said inner tubular element and an other of saidends thereof against said outer tubular element when said exhaustconnector is mounted between two said segments, said bellows therebyconfigured for biasing said inner tubular element against one of saidsegments and for biasing said outer tubular element against an other ofsaid segments; and an installation/removal tool for moving said innertubular element relative to said outer tubular element, said toolincluding an elongate member defining a longitudinal axis and a pair ofjaws carried by said elongate member, at least one of said jaws beingmovable relative to an other of said jaws in a direction parallel tosaid longitudinal axis, one of said jaws configured for connection withsaid inner tubular element and an other of said jaws configured forconnection with said outer tubular element, said inner tubular elementbeing relatively movable with said one of said jaws and said outertubular element being relatively movable with said other of said jaws.2. The exhaust connector kit of claim 1, wherein said elongate membercomprises a threaded rod which is threadingly connected with at leastone of said jaws.
 3. The exhaust connector kit of claim 2, wherein saidthreaded rod comprises a bolt, one said jaw slidably carried by saidbolt and an other said jaw threadingly engaged with said bolt.
 4. Theexhaust connector kit of claim 1, wherein each of said inner tubularelement and said outer tubular element include and end face with aradially outwardly projecting extension, one of said jaws including anabutment face for engaging one said extension and an other said jawincluding an abutment face for engaging an other said extension.